Device for casting small ingots with endless belt providing temporary mold side wall



Jan. 27, 1970 JQCHAM'BRAN 3,491,828

DEVICE FORCASTING SMALL INGOTS WITH ENDLESS BELT PROVIDING TEMPORARY MOLD SIDE WALL Filed Jan. 19, 1968 7 Sheets-Sheet 1 IN VENTOR d c QUEJ (HAMBRAN BY wam a, 710% M 4% Jan. 27, 1970 .LCHAMBRAN 3,491,823

DEVICE FOR CASTING SMALL meows WITH ENDLESS BELT PROVIDING-TEMPORARY MOLD SIDE WALL Filed Jan. 19, 1968 7 Sheets-$heet 2 J. CHAMBR'AN 3,491,328 TING SMALL INGOTS WITH ENDLESS I BELT PROVIDING TEMPORARY MOLD SIDE WALL Jan. 27, 1970 7 Sheets-Sheet 3 DEVICE FOR GAS Filed Jan. 19, 1968 FIG.4

FIG. 5

Jan. 27, 1970 J. CHAMBRAN 3,491,823

. DEVICE FOR CASTING SMALL INGOTS WITH ENDLESS BELT PROVIDING TEMPORARY MOLD SIDE WALL Filed Jan. 19, 1968 7 Sheets-Sheet 4 1970 J. CHAM-BRAN DEVICE FOR CASTING SMALL INGOTS WITH-ENDLES BELT PROVIDINGTEMPORARY MOLD SIDE WALL Flled Jan 19, 1968 7 Sheets-Sheet 5 FIG.7

Jan. 27, 1970 J. CHAMBRAN 3,491,328

. DEVICE FOR CASTING SMALL INGOTS WITH ENDLESS BELT PROVIDING TEMPORARY MOLD SIDE WALL Filed Jan. 19, 1968 7 Sheets-Sheet 6 United States Patent 3,491,828 DEVICE FOR CASTING SMALL INGOTS WITH ENDLESS BELT PROVIDING TEMPORARY MOLD SIDE WALL Jacques Chambran, Villers-la-Loue, Belgium, assignor to Pechiney, Compagnie de Produits Chimiques et Electrometallurgiques, Paris, France Filed Jan. 19, 1968, Ser. No. 699,102 Claims priority, application France, Jan. 24, 1967,

Int. c1. 1322a /02 US. Cl. 164-326 17 Claims ABSTRACT OF THE DISCLOSURE A device for casting small ingots comprising a horizontally disposed circular cell pl=ate mounted for rotational movement about a vertical axis and having a plurality of cells arranged in circumferentially spaced apart relation about the periphery of the blade in which each of the cells is open at the top and at the outer peripheral sides, a second circular plate mounted for rotational movement about a vertical axis and an endless belt operative between said plates to engage peripheral portions thereof and providing a temporary outer side wall for the cells in the portions of the plate engaged by the belt, means for rotating the plates, a casting device overlying the cell plate with means for controlling the device for pouring molten metal sequentially into the cells after they have become engaged by the belt and an ejection device positioned to effect lateral displacement of the cast metal ingots from the cells after disengagement by said belt.

This invention relates to equipment for casting small ingots.

Foundrymen, particularly those engaged in the manufacture of small objects from metals or alloys having low or moderate melting points, such as zinc, aluminum, magnesium, alloys of magnesium, brass and the like, have need of small ingots of the metal, weighing on the order of about 500 grams to 2 kilograms.

Such ingots can be cast with conventional casting machines designed for casting normal ingots weighing on the order of kilograms but the output is low, inefficient use is made of the machines and the cost of the metal is thus greatly increased. For these reasons, manual casting is often used but such manual labor constitutes hard work and expensive work.

It is an object of this invention to provide a simple and inexpensive device capable of high output and substantial economy in the cost for casting ingots.

These and other objects and advantages of this invention will hereinafter appear and for purposes of illustration, but not of limitation, embodiments of the invention are shown in the accompanying drawings in which FIG. 1 is a diagrammatic elevational view of equipment for casting small ingots in accordance with the practice of this invention with a single cell plate;

FIG. 2 is a sectiontal view taken along the vertical axial plane of the plate shown in FIG. 1;

FIG. 3 is a sectional view taken along the line A-A through a cell in the plate of FIG. 2;

FIG. 4 is a plan view of the plates and endless belt in the single plate system shown in FIGS. 1 and 2;

FIG. 5 is a schematic elevational view showing a modification with two active plates;

FIG. 6 is a plan view similar to that of FIG. 4 of the two active plates and endless belt;

FIG. 7 is a plan view of the casting device;

FIG. 8 is a side elevational view of the device shown in FIG. 7 as seen from a radial direction;

FIG. 9 is an elevational view of the device shown in FIG. 7 as seen from a direction tangent to the plate; and

FIG. 10 is a sectional view of the ejection device.

The equipment embodying the features of this invention comprises in combination and mounted on a support:

A circular plate mounted for turning movement about a vertical axis and provided in its periphery with a plurality of cells each of which has a bottom wall and three vertical side walls, an open top and an open peripheral side;

Another circular plate which is also mounted for turning movement about its vertical axis;

An endless belt applied to the external peripheries of the two plates and providing a temporary fourth vertical side wall for the cells in the plates;

A reducing motor connected to rotate at least one of the plates;

A belt tightcner;

At least one device for casting ingots; and

At least one device for ejecting ingots.

In accordance with a preferred embodiment of the invention, the device also has at least one of the following characteristics:

A device for pouring into the cells which consists, on the one hand, of a spout integral with an arm pivoted about a vertical axis, the arm also having a roller capable of working in unison with cams attached to the circular cell plate, an adjusting device which pushes the roller against the cam and, on the other hand, an intermediate stationary supply tank having a pouring nozzle.

The device, as shown in FIG. 1, is mounted on a base 1 formed of a table 11 and a vertically disposed support column 12.

The assembly 2 consisting of the first plate 21 and its attached devices is mounted on the base 1. The plate proper comprises two rigid metal disc-shaped sheets including an upper sheet 211 and a lower sheet 212 joined together by a peripheral cylindrical metal section 213. The peripheral portion of the upper sheet is cut out to accommodate the plurality of cells 215 circumferentially spaced apart in the peripheral portion thereof. Each cell, as shown in FIG. 2, consists of a metal sheet 2151 bent to U-shape in cross-section and closed, and its inner end turned towards the axis of the plate by a metal sheet 2152. The disc sheets 211 and 212 extend outwardly slightly beyond the peripheral sheet 213 to define therebetween a grooved pulley.

In order to make it possible to cool the cells with a cooling fluid circulated under pressure, the space between the two disc sheets 211 and 212 is subdivided into two compartments by a separator 214 consisting of a thin sheet having a central portion 2141 in the form of a cylindrical container without a cover and having a dished bottom, a median portion 2142 in the form of a disc perforated at its center along a circle and joined to the outer edge of the central portion, an exterior cylindrical portion 2141 joined along its upper base with the outer edge of the central portion, and finally a plane exterior portion 2144 in the form of a disc perforated at its center and joined to the outer edge of the exterior cylindrical portion. The separator 214 is supported in place by vertical brackets 2145 welded on one side to the separator and on the other side to the lower sheet 212.

The plate 21 is supported on a vertical tubular shaft 22 subdivided into two parts. The upper part 221 is attached to the upper sheet 211 of the plate while the lower cylindro-conical part 222 is connected to the lower sheet 212.

In order for the plate to turn freely about its axis 220, the upper tube section 221 is joined with the lower element 231 of a bearing 23. The exterior portion 232 of the bearing is attached to the end of the supporting column .12 on the base 1. Within the tube 21, there is provided a tube 24 for the supply of cooling fluid, such as water. Tube 24 is attached by means of a support 241 to the supporting column 12 and it extends into the tube 221 through an upper swivel joint 242 which allows the plate to rotate while the tube 24 remains stationary.

The lower tubular shaft 222 comprises an upper portion 2221 of large diameter, for example a diameter which is equal to that of the tube 221, and a lower portion 2223 of smaller diameter joined by a median truncated conical section 2222. The tube 2221 is attached at its upper portion to the lower sheet 212 of the plate. A gear 25 extends outwardly of the tube for engagement with power operatcd driving means to rotate the plate. A bearing 26 having an outer portion 261 is mounted on the table 11. The truncated conical portion 2222 bears, by means of a collar 272, against a stop 27, the outer portion 271 of which is connected to the bearing 26.

It will be noted that the ,upper sheet 211 is fastened to the upper tubular shaft 221 by means of heavy brackets 2111 and that the lower sheet 212 is fastened to the lower tubular shaft 2221 by brackets 2121.

A tube 28 extends beneath the table 11 for discharging the cooling fluid. The tube 28 is joined to the lower portion 2223 of the tubular shaft 222 by a lower swivel joint 282 having a tightening fitting 2821 which is pressed between a stationary element 2822 integral with the table 11 and an element 2823 which screws into the stationary element. A plastic joint 2824 separates the two elements.

The arrow 200 indicates the direction of flow of the cooling fluid. It will be understood that the direction of circulation can be reversed. In the example shown in FIG. 2, the cooling circuit to the various cells is arranged in parallel between the tube 24 which supplies the cooling fluid and tube 28 through which it leaves. It is also possible to connect the various cooling devices in series in which the fluid, which arrives through the tube 24, passes between sheets 211 and 2142 to cool the first cell 215, and then returns between the sheets 2142 and 212 tOl pass into the cooling circuit of the second cell, thence into that of the third, etc. Only on leaving the last cell im mediately preceding the first cell 215, does the fluid rejoin the outlet tubing 28.

As shown in FIG. 1, the table 11 also supports a motor driven reducer 29 which, by means of pinion 291, operably engages the gear to effect rotational movement. It is desirable for the reducer to have means for adjustment of the ratio in order to give the equipment maximum flexibility.

Each cell 215 repersents an ingot mold which is open on one of its vertical sides situated at the periphery of the plate. This side is adapted to be closed by an endless belt 3 which, as shown in FIG. 4, presses against the peripheral surface of the plate 21 and passes around the second plate 41.

When the plate 210 is driven by the moto-reducer 29 in the direction indicated by the arrow 201 in FIGS. 4-6, each cell is closed by the belt 3 from the time that it occupies the position shown by the reference mark 216 until it arrives at the position 217. This time span is calculated to correspond to the time required for casting of the metal into the cell and solidification of the metal. Thereafter, as the plate continues to turn, the cell moves to position 218 wherein its peripheral side is no longer closed by the belt. The metal continues to cool and, because of shrinkage due to solidification and cooling, the vertical back face of the ingot tends to draw away from the corresponding face 2152 of the cell, so that the ingot can be easily ejected, as by means of an ejection tool into the gap between the ingot and the face 2152 or by blowing compressed air into the gap.

In the embodiment shown in FIGS. 1 and 4, the second plate 41 consists of a simple pulley, the diameter of which is preferably less than the diameter of the first plate in order to realize maximum recovery by the endless belt.

In this arrangement, only the first plate represents the cell plate used for casting. Y

The pulley 41, which constitutes the second plate, is supported by an end bearing 42 fixed to a carriage 43. The carriage itself is supported on four wheels, rollers or balls, represented by the numerals 431 and 432, supported for free rotational movement on rails 441 on the upper surface of a pulley support 44. The carriage also has at its lower end counter-rollers 433 which ride against the lower surface of rails 442.

Tightening of the belt 3 can be accomplished by adjustment of the carriage 43 as by the use of a force constantly urging the carriage 43 in a direction away from the first plate. One such means illustrated in the drawings comprises a counter-weight 45 suspended from the end of a cable 451 which is fastened at its other end to the carriage while the intermediate portion passes over a pulley 452. Instead, use can be made of elastic means of adjustment such as spring means constantly urging the carriage in the desired direction.

The assembly 4 of the pulley 41 and its attached members is supported on table 46 forming a part of the base 1 of the device.

In another embodiment of the invention, illustrated in FIGS. 5 and 6, the second plate 51 is of the same construction as that of the first plate 21. Both plates represent cell plates which may be used for casting thereby to double the rate of production of the equipment. It is preferable for only one of the plates to be driven in rotational movement while the other is rotated by the endless belt 3. The unit 5, consisting of the second plate 51 and its attached devices, is the same as the described unit 2 formed of the first plate 21 and its attached de vices. Description of the unit 5 can be derived by substitution in the description of FIGS. 2 and 3 of the numeral 5 for the first numeral 2 in all of the reference marks except that the gear 25, the pinion 291 and the mote-reducer 29 do not have their counterparts in unit 5; The tension on belt 3 can be adjusted either by displacement of one of the plates or by adjustment of one or more of the conventional idler rollers in engagement with the belt, such as shown in FIG. 6. It will be understood that this system of tension control can also be employed in the embodiment shown in FIG. 1 thereby to make the carriage adjusting device superfluous and the carriage 43 can then be fixed to the support 44.

When the plate 21 is rotated in the direction of the arrow 201, the plate 51 is actuated by the belt 3 in the direction of the arrow 501. Thus two zones are defined on plate 21 in which one corresponds to the zone for casting and solidification of the metal situated between cells 216 and 217 and the other corresponds to the cooling and ejection of the ingots situated between cells 217 and 216. Similarly, the cell space 516 and 517 may be defined on plate 51 to define the closed cells effected by the belt and having the same role as cells 216 and 217 of the first plate. The zone of the plate 51 situated between cells 516 and 517, with rotation in the direction of the arrow 501, corresponds to casting and solidification of the metal while the zone between the cells 517 and 516 corresponds to the cooling and ejection of the ingots.

With a view towards obtaining maximum output from the equipment it is desirable for the zone of casting and solidification to represent as large a fraction as possible of the periphery of the cell plate. Pulleys 31 and 32 are provided for this purpose and, in addition, they serve to tighten the belt 3 when pulled in the direction towards one another by elastic means.

The second plate is supported on base 10 which can be identical with that of base 1 of the first plate.

The casting device 6, shown in FIGS. 7-9, comprises a support 61 consisting of a horizontal table 611 having two brackets 612 and 613 fixed with the table 11 of base 1. A mobile casting element '62 is provided consisting of an arm 622 articulated on the table 611 by means of an end bearing 621. The arm 622 supports a casting spout 623 anda roller 624.

.The active plate 21, which turns in the direction indicated by the arrow, carries the cells in which, in FIG. 7, the cell 218 is in casting position while the cell 219 precedes it. A cam is disposed between adjacent cells for the purpose of functioning together with the roller 624. Thus, between cells 218 and 219 there is a cam 631 and preceding cell 219 there is a cam 632.

The spout is positioned against cam 631 by an adjusting device such as a simple spring. The device 64 comprises a grooved idler pulley 641 mounted on a support 642. A cable 643 passes over the pulley and is fastened at one end to the arm 622 while the other end supports a counterweight 644.

About the spout there is an intermediate supply tank 651 provided with a pour nozzle 652. The assembly of the tank with its nozzle is internally lined with a layer 6511 of refractory material. The tank 651 is mounted on a column 653 which can be oriented and adjusted for height. Only the nozzle 652 is shown in FIG. 7 for pur poses of clarity.

The tank 651 is so mounted that, if the spout 623 were absent, the metal flowing from the nozzle 652 would flow into the cells as they pass underneath one after another. However, between the two cells, the liquid metal will flow onto the sheet 211 of the plate in the absence of the spout.

When a cell 219 appears before the spout, the roller 624 remains in contact with the cam 631. As the plate turns with-a uniform movement in the direction of the arrow 201, the cam 631 pushes the roller back so that the spout is carried along with the movement of the plate and the molten metal pours through the nozzle 652 into the spout and from the spout into cell 219. This manner of pouring continues until the open front of the spout comes opposite the nozzle and thereafter the metal flows directly from the rgolzzle but always into the cell 219 located immediately e ow.

When the cell 218 reaches the place previously occupied by cell 219, the spout occupies position 6231. The nozzle is disengaged and pours directly into cell 218. At the same time, the roller 624 assumes its position at 6241, the cam 631 arrives at 632 to release the roller. The counterweight 644 withdraws the spout until the roller comes into contact with the following cam 630 which, at that time, occupies the position previously occupied by cam 631. Thus the spout resumes its position under the nozzle. The cell 218 is no longer being fed while the following cell which has taken the place previously occupied by the cell 218 is receiving the cast metal.

The intermediate tank is fed molten metal from a casting furnace, preferably at constant level. Ingots of the desired mass are cast by controlling this level which is a function of the speed of rotation of the plate.

Finally, the equipment comprises an ingot ejection device which, in the illustrated modification, consists of a wide-nosed nozzle 66 supplied with a compressed gas, such as air. As shown in FIG. 10, the ingot undergoes shrinkage during solidification and cooling such that it acquires the shape shown by the reference numeral 21 50 with a void formed between the back vertical wall 2152 of the cell and the ingot. It is sufiicient to blow compressed air into the gap to cause the ingot to be displaced from the cell and fall into a packing case alongside the plate in front of the nozzle.

It is preferred that the casting device be placed, as shown in FIG. 6, so that casting takes place at 216 and respectively at 216 and at 516 in the modified assembly, and that the ejection device be placed in a location wherein the cell is not closed by the belt 3, preferably on the axis shown or somewhat beyond that axis in the direction of cell 216, or 216 and 516.

It will be apparent from the foregoing that there is provided a simple and efficient device for the casting of small ingots of molten metals, which device makes use of substantially automatically operating components thereby to permit high speed production of the ingots of low cost.

It will be understood that changes may be made in the details of construction, arrangement and operation without departing from the spirit of the invention, especially as defined in the following claims.

I claim:

1. A device for casting small ingots comprising a horizontally disposed circular cell plate mounted for rotational movement about a vertical axis, 'a plurality of cells arranged in circumferentially spaced apart relation about the periphery of the plate with the cells being open at the top and at their outer peripheral sides, a second circular plate mounted for rotational movement, an endless belt about peripheral portions of said plates for interconnecting said plates and providing a temporary outer side wall for said cells in the portions of the cell plate engaged by the belt, means for effecting linear displacement of the belt with corresponding turning movement of the cell plate, a casting device overlying the cell plate, means controlling the device for pouring molten metal sequentially into the cells after they have become engaged by the belt, and an ejection device positioned to effect lateral displacement of the cast metal ingots from the cells after disengagement by said belt.

2. A device as claimed in claim 1 in which the second circular plate is also mounted for rotational movement about a vertical axis.

3. A device as claimed in claim 2 in which the means for effecting linear displacement of the belt comprises a motor and an operative connection between the motor and one of said plates for rotational movement of the plates about their axes.

4. A device as claimed in claim 1 in which the endless belt has a width at least as great as the height of the open outer wall of the cell to define the outer wall thereof during engagement by the belt.

5. A device as claimed in claim 1 in which the ejection device comprises an ejection pin.

'6. A device as claimed in claim 1 in which the ejection device comprises an air nozzle positioned to project an air stream downwardly and radially outwardly into the inner portion of the cells for outward displacement of the ingot through the open side of the cell.

7. A device as claimed in claim 2 which includes means for maintaining the belt in tensioned engagement with the peripheral portions of the cell plate.

8. A device as claimed in claim 7 in which the means maintaining the belt in tensioned engagement with the cell plate comprises mounting the second plate for movement in a direction toward and away from the cell plate and counterweighted means connected to the second plate constantly urging the second plate for movement in a direction away from the cell plate.

9. A device as claimed in claim 7 in which the means mounting the belt in tensioned engagement with the cell plate comprises idler rollers mounted for free rotational movement between the plates and in the path of travel of the two runs of the belt between the plates with the belt trained about the inner peripheral portions of the idler rolls, and means for adjustment of at least one of the idler rolls in the direction towards the other.

10. A device as claimed in claim 1 in which the cell plate comprises spaced upper and lower circular metal sheets and a peripheral cylinder member joining the upper and lower sheets at their outer peripheries.

11. A device as claimed in claim 10 in which the pcripheral cylindrical member is spaced a distance inwardly from the peripheries of the circular sheets to define a grooved pulley section therebetween.

12. A device as claimed in claim 10 in which the upper sheet is cut out in the cell portions for receiving cells in fitting relationship therein and which includes cell members in said out out portions.

13. A device as claimed in claim 12 in which the cells comprise dished members having bottom, side and back walls but without a front wall.

14. A device as claimed in claim 10 which includes a separating member subdividing the space between the two circular sheets into connected upper and lower compartments, and means for circulating a cooling fluid through said plate from one compartment to the other.

15. A device as claimed in claim 14 in which the ci cuit for the cooling fluid is arranged in series sequentially to cool the cells.

16. A device as claimed in claim 2 in which the second plate constitutes a cell plate which is the same as the other cell plate.

17. A device as claimed in claim 1 in which the casting device comprises an arm mounted for pivotal movement about a vertical axis, a pouring spout integral with one end of the arm, cam members on the cell plates with one cam associated with each cell, a roller carried by the arm in position to engage the cams and an adjustable means References Cited UNITED STATES PATENTS 2,865,067 12/1958 Properzi 164--283X 3,200,451 8/1965 Worswick 164-326 X ROBERT D. BALDWIN, Primary Examiner US. Cl. X.R. 164336, 348, 344 

